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Master Control Software Figure 7. Simplified One Line Diagram of the ORC Units In order to integrate the ORC units into the evaporative cooling circuit of the Tosçelik Slab Furnace, it was necessary to provide a regulating loop to ensure that the ORC units extracted the optimum amount of heat from the evaporative cooling system. The control loop was implemented in a PLC. An HMI server and screens were added for remote operation and monitoring of the waste heat recovery system. Main functions of the control loop: a) Ensuring optimum resource inlet temperature for the ORCs for maximum power efficiency at different furnace operating conditions b) Preventing ORC units from removing too much heat and inducing cold spots into the slabs that are resting on the furnace skids. c) Balancing power generation between ORC units The above was achieved by sending a power generation set point to each ORC unit. The power setpoint was calculated in the PLC based on available excess heat by comparing the actual drum water temperature with an HMI screen input reference for desired drum temperature (Figure 8). If the actual drum temperature is higher than the set point, this would mean there is excess heat in the system and ORC units could extract more heat and generate more power. The amount of excess heat is calculated by using the total amount of water flow and the difference between actual drum temperature and the HMI screen reference. In addition to increasing or decreasing the power set point, the control algorithm includes additional features such as turning off an ORC unit in case the unit’s minimum power limit was reached as well as turning on an additional ORC unit in case all operating units were at maximum power and there was still excess heat available in the system. In and out of service selection from the HMI screen (Figure 9) determined which units would be available for power generation. However; due to the long time constant of the process, the power generation set point was changed at a very slow rate to avoid introducing oscillations or creating instability in the system.PDF Image | Novel Application of Organic Rankine Cycle (ORC) Technology for Waste Heat Recovery from Reheat Furnace Evaporative Cooling System
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